Process for hydrocarbon conversion



July 11, 1944. w. A. scHuLzE ET AL 2,353,509

PROCESS FOR HYDRO-CARBON CONVERSION Filed Feb. e, 1942 CARL J. HELM Rs M no? Patented July 11, 1944 UNITED STATES PATENT OFFICE PROCESS FOR HYDBOCARBON CONVERSION Waiter A. schulz@ and cui J. Heimen, Bmmville, Okla., assignora to Phillips Petroleum:

. i Company. a corporation of Delaware Application February s, i942, serial No, 429,813

(Cl. 19t-52)` 12 claim.

' `This invention vrelates to the catalytic treatment ot hydrocarbons, 'and more particularly it 'relates to such catalytic endothermic reactions as "cracking, dehydrogenatiom reforming, and the like, which are promoted by `contact catalyst masses. i l

'One' of themain problems in catalytic reactions promoted by solid contact catalysts'which occur with absorption of'heatis to maintain the temperatureat the desired level throughout the whole catalyst mass.` `I't'the charge is preheated so that it has thede'sird temperature at the entrance of the catalyst'bed, a2-serious drop in temperature vis ordinarily notedin'the latter parts of the catalyst traversedbythefmaterials undergoing conversion.l This diminishing of the temperature of ""2 the chargeas it passes through the catalyst mass j is probablycausedto a large extent by the endo-:-

thermicnature' ot'fthe reaction, and itis often magnied-byg'thrfact that relatively large cata- I lyst masses must be employed to insure' the proper contact timenecessary I or the hydrocarbon conversion. As the optimum temperature` m'ay'not maintained in a large portionof the catalyst chamber, there is a decrease in conversion which notonly may lower the yield to an economically `unsatisfactoryl level but may produce a product 'ofinferior' quality. If it is attempted to maln. tainithe" average temperature of the' reactants in the desiredgrange throughoutthe catalyst by in- Qtroduction 'at temperatures above fthe optimum fleveLfthe Vamount vof superheatin'g of the feed. stock that is necessary will often cause undesr.

ablejthermal cracking in the preheater and in the lines to the catalyst chamber. Systems have beendescribed for indirect heat exchange within i Athe'catalyst mass by means 'of radiators and the like-carrying heat transfer fluids, but the complerrity'v of such equipment and of its operation .y f introduces tremendous engineering problems and l :greatly increased process costs.` l' The addition to the `hydrocarbon charge of relatively heat-stable gases and vapors which are substantially unconverted at reaction conditions .l is one means of reducing endothermic heat losses .4 within the catalyst bed.l These diluents which may be premixed with the reactants or added lthereto at or even somewhat above conversion` temperatures then serve to maintain'or restore conversion temperatures by supplying sensible side ofthe catalyst'chaalbenv disadvantage in this procedure, however, is 4tliefactor of dilution by the ,added volume fof such Lmaterial and itsleflect onvapo'r velocityand theleii'ective contact or reaction time 9i` lreactantsfwithinthe catalyst. V`For instancelfas themeation mixture passes through v the catalysty rusas.,v it becomesginl creasingly more dilute'lwith respect-to the hydrocarbon reactant because ofl thecontinued introduction of theheat `carrier diluent. dilution `may reach a point wherethe contact time betweenfthelhydrocarbon andy-the catalyst is so small aslto materially-:lowerthe etllciency of the conversion andthe quality oi the'product.

The present 'inventionlhas for one object an v@improved process vfin-the. maintenance oi a con- 4-stanthigh conversion level throughout the catalyst mass 1n 'a catalytic"encontrarme-,reaction or the type described'.

y Another )meet 1ste" pr'fvidja improved procjess for the useof substantlallyinert heat carrier 'fluids' inl maintaining conversion Vvtemperatures Within'tcontactratalystmasses.

A further' object ci" thisfinvention 4ishto provide anv impro ved' process vfor" simultaneously mainvthe" cntact'time between catalyst and reactant andthe conversion temperature within a narrow' ranse in'fa catalytic endothermlc reaction. These and other objects and advantages or the invention will beobvious from the disclosure to follow. A still further object ofthe invention is to provide a novel'arrangenient of the catalyst mass Iori endothermic fconversions of hydrocarbons wherein successive incrementsI of the` mass have increasing volume as the volume of the vapor stream traversing'the bed increases.

lAnother object oi thisinventin is to provide s. process for the endothermic conversion of hydrocarbonsA in a catalyst 4bed wherein intermediate injections oiinert heating medium are correlated with the increasing volume of catalyst in the direction of flow to maintain the reaction temperature; We have now discovered that in catalytic endothermic conversions wherein substantially in? ert heat carrier uids are added at a plurality heat directly to the reactants within the catalyst mass. Itis often desirable to introduce substantially inert heat carriers into the conversion zone through a plurality of inlets spaced along the of inlets along the catalyst chamber in order to maintain the temperature,A the contact time between catalyst and hydrocarbon can be kept approximately constant by increasing the volume of catalyst in successive increments of the conversionzone by an amount proportionate to the increase in the total vapor volume. Thus as the throughout the whole catalyst mass.

total volume of the reaction mixture increases,

and as it becomes more dilute with respect to theconvertible material, it comes in contact with a proportionately larger volume of catalyst, and

the contact time between the hydrocarbon feed and the catalyst remains satisfactorily uniform Hence, by

means-of this process, avery high degree of cony l version is obtained in,each of the increments of s the catalyst mass. Also, since the proper conditions necessary 'for the desired conversion are more nearly approached throughout the. whole catalystl bed, a product of better qualityI is obtained. Another advantage oi this process is that its objects are achieved without the employment of any unduly complex equipment and consequently the engineering problems and process costs are cut to a minimum.

In one specific embodiment, our process comprises the steps of (1) preheating a hydrocarbon charge,vwith or without previous addition of relatively inert or refractory diluent, to substantially conversion temperature; (2) passing the charge through a body of catalystcomposed of a plurality of more or less separate sections of progressively increasing volume in the direction of vapor ow; (3) adding at one or more points beto suit any particular charge stock and convertive reaction.

Instead of obtaining the requisite volume increase by greater -sectional depth, an arrangement similar to Figure 2 may be applied. In this diagram the catalyst chamber 1 is divided into four sections of successively increasing vol- .ume butof more or less uniform depth, and the volume increase is obtained by greater diameter of the successive sections. The relative increase ofA diameter in the separate sections as shown in the drawing is greatly exaggerated for purposes of illustration. In actual practice, we prefer the relationship of the section diameters to be 0.5', 0.87, 1.12, and 1.37. Operation. of this chamber is identical with that described in connection with Figure 1, and the pressure drop through the entire bed is somewhat lessened by the decreased total bed depth.

' that the progressive changes in each dimension tween said catalyst sections superheated subance with the ilow diagram of Figure 1. This diagram shows an arrangement of equipment for a catalytic conversion of a hydrocarbon stock utilizing one possible catalyst arrangement as disclosed by the present invention.

The hydrocarbon charge enters by line I and is heated in preheater 2 prior to introduction to the/conversion zone. Adiluent or heat carrier The heated charge alystl chamber 1 and additional amounts of diluent may be added to the transfer une just ahead of the catalyst through line 5 and valve 8. The heated diluent passing through line 5 is raised to satisfactory temperature level usually somewhat above that in the catalyst chamber by passage through a heating coil in preheater 2 or in any other convenient manner.

The body of catalyst in chamber 'l is divided into a number of increments or sections of increasing volume in the direction of vapor flow, with four such increments, A to D, being illus- `trated. The reactanit vapors after passage vthrough each increment are mixed with additional amounts of superheated diluent from line 5 anda series of perforated branch lines and valves 9 extending into the free space between sections of the' bed. The catalyst effluents are taken through line l!) and valve H to fractionators and other process equipment for the separation of diluent, products and unconverted material.

This type of catalyst chamber is very satisv factory in conversions which are favored by a relatively lar'ge ratio of catalyst bed depth to cross-sectional area. This arrangement may be extended to include any desired number of sec tions with the relative depth and volume of each section as well as the total depth being chosen may be added :to the charge ahead of 4the prex v; heater through lines 3 and 4.

mixture then passes' by transfer line 6 to catare cooperative. This type of bed enables the maintenance of suitable total bed depth and at the same time prevents excessive pressure drop in both conversion and reactivation operations.

'I'hese and other possible modiilcations of the above-described catalyst arrangements, includy ing the disposition of the individual sections in separate chambers placed in senies, will be discernible by those skilled in the art.

While various mechanical features of the catalyst chamber design and construction may be evolved X from the foregoing disclosure, it is ordinarily preferred to arrange the catalyst in vertically spaced sections supported on trays or porous supporting members in chambers or towers of more or less conventional design. Then the free space between one supporting member and the top of the next lower section is available for injection of the heat carrier gases through any mixing and/or distributing devices which may be desirable to obtain rapid diffusion with and heat transfer to the vapor stream. Such ports or mixing devices are likewise available for fluid injection in other phases of the process such as the catalyst reactivation operation.

As indicated above, it is often desirable to add a diluent or substantially inert material to the hydrocarbon charge ahead of the catalyst zone, and even ahead of the preheater. This diluent may be the same as that employed for direct addition into the catalytic zone, or it may be a different material derived from an entirely separate source such as processing operations which produce the charge stock. However, it is ordinarily possible and satisfactory to employ the same diluent material for both applications.

The volume of diluent that is added ahead of the catalytic zone is ordinarily limited to that amount which produces benecial operational eiects without causing uneconomic increases in equipment size and the cost of handling and sepparating an inert material. Thus, in the catalytic cracking of relatively heavy hydrocarbon oils such as gas oil, reduced crudes and the like, it is desirable to introduce relatively large volumes of diluent at the start to reduce the charge viscosity and coking and thermal cracking in the preheater.` In reforming, dehydrogenation and the like, when lighter more refractory stocks such as gasoline or light `hydrocarbons are treated. the presence of diluents at this stage is usually of less importance. Further amounts of diluent may be desirable in all cases in order to satisfy predetermined reactant-diluent ratios for1 the conversion, and such amounts may be added ahead of the catalyst, exclusive of the volume of diluent employed for the temperature control within the conversion zone.

In the catalytic cracking of gas oil to produce `lighter products, it is often preferred to add a considerable portion of the overall volume of diluent ahead of the preheater and then to add suf- `ilcient superheated diluent justI ahead of the catalyst chamber 'to balance transfer line heat losses. An lalternative method is to preheat the hydrocarbon charge to a temperature somewhat below conversion levels and to obtain conversion temperatures by admlxture with requisite volumes of the superheated diluent at the entrance to"the catalyst. l v

`Within `the catalyst chamber, the volume of superheated diluent to be added, and the number of injection .points are governed by the magnitude of the temperature drop. 'I'his temperature 1 drop is in turn dependent on such factors as the `heat of reaction, the extent of conversion, and

the concentration and specific `heat of any substantially inert material in the charge. The heat loss for specific conversions may be calculated or determined experimentally,- and the required voland it will be evident that a moreuniform and nearly constant temperature may be obtained by 'increasing the number of injection ports for the heat. control medium. However, for economic reasons involving the cost of equipment and the mechanical control of the process, the number of sections is ordinarily limited in practice and the temperature is controlled within certain desirable limits.

When the volumes of the sections of the catalyst bed have been calculated or determined experimentally in accordance with the above-described factors, these volumes are translated into corresponding depths of the catalyst in each section, depending, o! course, on the type of chamber employed. The minimum` depth of a single y generally to endothermic conversions over conume of superheated diluent similarly determined y to correspond to the desired degree of temperature control. The temperature control medium may be employed to substantially restore initial conversion temperatures ata series of points along l the catalyst body, or, as is usually more practical,

sufficient heat may be supplied to reduce the temperature gradient between any chosen reference points to values consistent with emcient conversion. For example, the temperature variation from catalyst inlet to outlet may be held within a range of about 10 to about 50 F. by the present invention. In contrast, under substantially adiabatic conditions, the corresponding temperature drop might range from about 70 to 100 F., even though considerable amounts of relatively inert'- diluent were premixed with the charge.

` The increase in total vapor volume within each` section of the catalyst bed due to the injection of the heat control medium is correlated in the present process with the increased volume of catalyst in that section. In this manner it is possible to wholly or partially compensate for the increase in vapor volume and to satisfactorily control the space velocity (standard gas volumes per volume of catalyst per unit of time) of the vapors. The increase in catalyst volume in the` successive sections of the bed is, therefore, proportioned to the volumeof superheated fluid injected above each section. The cumulative enact of this procedure is the catalyst arrangement illustrated above or a'varlation-thereof wherein each section is of a larger volume than the preceding one. -In nearly all conversions of the type described, there is a definite volume increase accompanying conversion. However, since this effect is accounted for in predetermined formulas for space velocity, contact time, etc., it does not always enter vinto calculations pertaining to the volume of catalyst sections for the present invention.

number of injection ports may be relatively large,

tact masses wherein heat transfer is wholly or partially a function of the vaporstream, it may be utilized with a great variety of catalytic materials and under a wide range of physical operating conditions. For example, it is capable of application in catalytic cracking, reforming, dehydrogenation and similar hydrocarbon conversions operated on stocks ranging from heavy reduced crudes to light normally gaseous hydrocarbons. In specific instances, such conditions as temperatures, pressures and flow rates will be chosen to conform to values known to favor the particular conversion.

In the cracking of gas oil and other heavy oils y to produce gasoline and light products, the operating temperatue may range from about 850 to about 1050 F., while the process pressures range from atmospheric to as high as about 1000 pounds gage. Conversions involving lighter.' generally more refractory stocks such as gasoline may require somewhat higher temperatures of 900 to l300 F., often with atmospheric or low superatmospheric pressures.

The materials which are suitable for use as diluents in our process are those satisfactorily heat-stable at the temperatures employed to perform the desired functions of reducing thermal decomposition in the preheating step and furnishing sensible heat to the reactant vapors in the catalytic zone. These materials include the light refractory hydrocarbons of up to five carbon atoms or various mixtures thereof, as well as gases such as nitrogen, carbon dioxide, steam and mixtures comprising them such as substantially oxygen-free `flue or combustion gases. Particularly desirable from the standpoint of availability and ease of separation from hydrocarbon products is steam, which may be considered our preferred diluent. Also suitable for many conversions are the light hydrocarbon mixtures comprising methane, ethane, propane, and butane in various ratios which are often available or may be produced in the conversion process. Or, instead of using a single type of diluent, different materials may be supplied to the process, in one case for admlxture with the charge ahead of the preheater, and in the other case, `i'or injection as a heat control medium into the catalytic zone.

'I 'he amount of diluent employed Will vary, according to the charge stock and the nature of conversion, from the minimum volume required for temperature control to as high as several hundred per cent by weight of the charge. For example, in cracking gas oil to produce gasoline, the diluent may amount to from about or less to about 100 or more per cent by Weight of the gas oil charge.

The contact catalysts useful in our process are those having activity in promoting the desired conversion, and particularly those rugged mineral ore materials comprising bauxite, brucite, various clay-type minerals and active aluminum silicates. These natural catalysts may be used after activation by various means and/or may be promoted with minor amounts of active metals or metal salts or oxides. Also useful are natural materials n comprising zirconia and titania, and synthetic ypreparations comprising zirconia, titania, magsections of the catalyst bed. The nal weight ratio of the gas oil charge to the diluent was 2:1 and minimum temperatures within the catalyst bed were substantially above 950 F. The per pass conversion during a two-hour on stream period averaged 44 volume per cent of the gas oil charge, with over 90 per cent of the converted material recovered as stabilized end-point gasoline.

When the original charge mixture (l0 per cent by weight of propane) -was charged'to a conventional type catalyst chamber containing the same volume of catalyst in a single section, the conversion dropped to about 28 volume per cent of the gas oil due to a temperature gradient `of from 985 F. at the catalyst inlet to 900 F. at the cat alyst outlet. i

, When a mixture containing the 'above-mentioned final weightratio (2:1) 'of gasoil and dil- -uent was charged under the 'same conditionsto the lsingle section catalyst bed. the per pass conversion was fonly-3l5 volume per cent of thegas oil.

, The temperature gradient'was from 985 F. atlthe inlet to 940 Fat thechamber outlet, but the tivation at controlled temperatures in an oxidizing y atmosphere. For this reactivation, it is usually preferred to pass oxygen-containing gases such as mixtures of air with steam, nitrogen, carbondioxide, or inert combustionrgas through the catalyst to burn ofi the materials responsible for deactivation without thereby producing combustion temperaturesv harmful to the catalyst. By pro.

The following examples, while kimplying nolimitation, illustrate speciilc -applications of theV invention to the catalytic cracking of heavy hydrocarbon oils, a conversion in which the process is of particular beneilt.

Example I A catalytic gas oil cracking operation on a charge having a specific gravity of 33 A. P. I. and a boiling range of 425-700 F, was conducted with a bauxite catalyst at a catalyst inlet temperature of 985 F. and a pressure of 70 pounds gage. Each catalyst case consisted of a 4foot diameter case divided into four zones separated by 4 inch free spaces and 'having the following lengths: 0.8, 1.8, 2.7, and 3.7 feet. Inlet tubes for injecting the superheated diluent were provided in the catalyst case Wall ai; the free spaces between the latter three sections. A total of 113 cubic feet of catalyst was used in each case. The gas oil diluted with l0 per cent by weight of propane was preheated to 985 F. and passed in vapor phase into the catalyst chamber at the rate of 1.0 liquid volumes of gas oil per volume oi catalyst per hour. The temperature at the end of the first Zone was 954 F. and l2 pounds of propane at l200 F. per each 90 pounds of hydrocarbon charged, were added to bring the temperature of the mixture to substantially 985 F. Similarly, about 12 pounds of superheated propane at l200 F; per every 90 pounds of gas oil charged were added through the other two inlets at the top of the third and. fourth mean space velocity was substantially higher'and 'decreased conversion resulted.

` v l Example 1r Acracking operation' using the 'same catalyst and gas oil charge as in Example'l 'was conducted wlthsteam diluent at a catalyst inlettemperature of 985 F. and a pressure of 75 pounds gage'.v Each catalyst case consisted of a 4' foot-diameter'case perature at the end of the rst zone was'952.- F.

and 17.3 pounds of steam at 1230 F. per 90 pounds y of hydrocarbonv charge were added-to bring-the temperature of the mixture to substantially-985 F. Similarly, about 17 poundsfof steam atv-1230u F. per every pounds ofgas oilswere injected through theA other two` inlets atA the top of the v third and fourth .sections of the Vcatalyst bed.

Thenal weight ratio of the gas oil chargeto the diluent was 1.4 to l. (mole ratio of l to v9.5`):and minimum temperatures in the catalyst bedwere substantially above 950 F. The perpasszconversion during a four hour on--stream period averaged 48 volume per cent of the gasoil charge, with over 92 per cent ofthe converted material recovered was stabilized end-point gasoline.

While the foregoing discussion and exemplary operations have served to illustrate our invention and some preferred applications thereof, it will be obvious to those skilled in the art that the -process described is of generalapplication and capable of numerous modifications within the broad scope .of the principles disclosed. Hence, no limitations are intended except as defined in the following claims. l.

We claim: L

1. A process for the endoth'ermic conversion of hydrocarbons over contact catalyst masses which comprises heating a hydrocarbon charge to substantially conversion temperature, passing the hydrocarbon in vapor form at a predetermined space velocity through a body of catalyst wherein conversion occurs with the absorption of heat, injecting into the body of catalyst at a series of points spaced in thekdirection of vapor flow suilicient substantially inert diluent heated to a temperature above said conversion temperature to supply a substantial proportion of the heat absorbed, successive increments of said catalyst bcfziy corresponding'to the intervals between successive points of addition of said diluent being increased `to correspond with the increased volume oi' said hydrocarbon vapor following each successive point oi addition of said diluent and the mean space velocity of the vapor ilow through the catalystbody being substantially maintained.

2. A process for the endothermic conversion oi' hydrocarbons over contact catalyst masses which comprises heating a hydrocarbon charge to a temperature sumcient ton initiate reaction. passing the heated hydrocarbon charge in vapor form through a body oi catahrst to promote the endothermic conversion, dividing said body of catalyst into a series oi increments oi increasing volume in the direction of hydrocarbon now. injecting into the hydrocarbon vapor stream at the point of entry to each of said increments of the said catalyst body a suilicient volume oi' substantially inert diluent heated above conversion temperature to restore a substantial proportion of the heat abstracted by the convertive reaction in the prior increment of said catalyst body, the catalyst volume in each said successive catalyst increment being increased in an amount proportional to the increased volume of hydrocarbon vapor due to the added volume of diluent injected therein.

3. A process as in claim 2 in which the hydrocarbon charge is premixed with a substantial amount oi a relatively inert diluent.

. 4. A process as in claim 2 in which the hydrocarbon charge is admlxed with a substancial amount of steam prior to the initial heating step and steam is further added to the catalytic zone during the conversion.

i 5. A process for the catalytic cracking of heavy hydrocarbons to produce lower boiling products which comprises heating a charge mixture comprising heavy hydrocarbons to substantially conversion temperature, passing the heated charge in vapor form at a predetermined space velocity through a body of cracking catalyst wherein conversion occurs with the abstraction ot heat,

said body oi' catalyst being divided into a plurality of separate increments ot progressively increasing volume in the direction of vapor flow, injecting into the hydrocarbon vapor stream at a plurality of points corresponding to free spaces .between said separate increments sumcient substantially inert diluent to supply a major proportion of the heat abstracted in the previously '1. A process as 1n claim 5 in which the charge mixture comprises a gas oil admixed with steam and steam is injected into the catalyst body.

8. An endothermic process for the `catalytic cracking of heavy hydrocarbons to produce lower 5 'boiling products which comprises pre-heating said hydrocarbons to form a gaseous charge at substantially conversion temperature, passing the gaseous charge through an elongated catalyst bed, injecting an inert heating medium at a plurality of points spaced in the direction of flow of said gaseous charge in said bed in sumcient quantity to maintain said gases at conversion temperatur'e, the volume of said catalyst in the bed between the points at which the inert heating medium is injected increasing in the direction of gas ilow.

9. An endothermic process for the catalytic cracking o1' heavy hydrocarbons to produce lower boiling products which comprises pre-heating 20 said hydrocarbons to form a gaseous charge at substantially conversion temperature, passing the gaseous charge through an elongated catalyst bed, injecting an inert heating medium at a. plurality o! points spaced in the direction of ow of said gaseous charge in said bed in sumcient `quantity to maintain said gases at conversion temperature, and increasing the volumes ot catalyst succeeding each point of injection with rality oi successive increments of catalyst at a predetermined space velocity, each successive increment in the direction of 4now having an increased volume, and adding a heating gas between said increments to maintain said hydrocarbon charge at conversion temperature, the

mean space velocity oi the hydrocarbon vapors being substantially the same for successive increments of catalyst.

11. A process for the endothermic conversion or hydrocarbons over contact catalyst masses which comprises heating a hydrocarbon charge to substantially conversion temperature, passing the hydrocarbons in vapor form through a pluso rality of successive increments oi' catalyst, each successive increment in the direction of ilow having an increased volume and adding a heating gas between said increments to maintain said hydrocarbon charge at conversion temperature. 12. An endothermic process for the catalytic cracking of heavy hydrocarbons to produce lower vboiling products which comprises pre-heating said hydrocarbons to form a gaseous charge at a temperature of from 850 to 1300I F., passing o the gaseous charge through an elongated catalyst bed, injecting an inert heating medium at a plurality of points spaced in the direction of now of said gaseous charge inlaid bed in sumcient quantity to maintain said gases at conversion 65 temperature. the volume ot said catalyst in the bed between the points at which the inert heating medium is injected increasing in the direction o! gas flow.

WALTER A. SCHULZE.

1o CARL J.

the hydrocarbons in vapor form through a plu-` 

